Collapsible Containers

ABSTRACT

Collapsible containers dimensioned to integrate into less-than-load operations are provided. The container may include a base, a pair of first and second opposing walls, each first and second opposing wall including a top edge, two side edges and a bottom edge. The container further includes a top panel removably attached to the top edge of the pairs of first and second opposing walls and a plurality of engaging devices positioned along the perimeter of the base and along the two side edges and bottom edge of the pairs of first and second opposing walls. The plurality of engaging devices are configured to removably connect the pair of first opposing walls to the pair of second opposing walls and to removably connect the pairs of first and second opposing walls to the base.

TECHNICAL FIELD

The present invention relates generally to shipping and storagecontainers and methods, and in particular, embodiments relate tocollapsible containers that may be integrated into a motor carrier'scurrent less than load operations without any additional equipment ordisruption of service.

BACKGROUND

Containers are utilized by industry and consumers to ship freight fromone location to another. Containers are also commonly used to storeitems for a length of time. Conventional containers, although effectivewhen full of freight, become a source of lost revenue for a motorcarrier when the container is empty because the space taken up by theempty container could be used by a full container or other freight.Similarly, in the case of residential or commercial use, an emptycontainer undesirably takes up a great deal of space in a residential orcommercial user's basement, attic, storage space, warehouse or othersimilar location. A user may desire to keep an empty container in his orher possession for future use but for the undesirable space the emptycontainer requires.

Conventional containers are also difficult for a commercial orresidential user to load and unload. The top-loading of a shippingcontainer can be a harrowing experience, especially when the item to beshipped or stored is being loaded into a tall container. For example,the article may be accidentally dropped while it is being loaded intothe container from the top. Additionally, articles positioned at thebottom of a full top-loaded container may be difficult, if notimpossible, to locate or remove if the need arises.

Additionally, conventional containers are not easily integrated into amotor carrier's current less than load (“LTL”) operations. LTL freight,unlike full truckload freight, is collected from various shippers andconsolidated onto a trailer. Non-uniformity of conventional containerdimensions create inefficiencies in LTL linehaul operations by causinglarge gaps of dead space in between freight and containers. Similarly,conventional shipping containers are not dimensioned to fit in trailerswith overhead, roll-up doors.

Accordingly, a shipping and storing container that takes up minimumspace when empty, is easily loaded and unloaded, and integrates into LTLoperations is desired.

SUMMARY

According to one embodiment, a collapsible container is provided. Thecollapsible container includes a base, a pair of first opposing walls,each first opposing wall comprising a top edge, two side edges and abottom edge, a pair of second opposing walls, each second opposing wallcomprising a top edge, two side edges and a bottom edge, a top panelremovably attached to the top edge of the pairs of first and secondopposing walls and a plurality of engaging devices positioned along theperimeter of the base and along the two side edges and bottom edge ofthe pairs of first and second opposing walls. The plurality of engagingdevices are configured to removably connect the pair of first opposingwalls to the pair of second opposing walls and to removably connect thepairs of first and second opposing walls to the base. Further, thecollapsible container is dimensioned to integrate into less than truckload operations.

According to another embodiment, a collapsible container is provided.The collapsible container includes a pair of first opposing walls, eachfirst opposing wall including a top edge, a bottom edge comprising aplurality of bottom male fastening components, and two side edgesincluding a plurality of side male fastening components. The collapsiblecontainer also includes a pair of second opposing walls, each secondopposing wall including a top edge, a bottom edge comprising a pluralityof bottom male fastening components, and two side edges comprising aplurality of side female fastening components configured to accept theplurality of side male fastening components. A base including aplurality of base female fastening components along a perimeter of thebase, the plurality of base female fastening components configured toaccept the plurality of bottom male fastening components of the pairs offirst and second opposing walls and a top panel configured to removablyattach to the top edge of the pairs of first and second opposing wallsare also included. When the collapsible container is in an erectedposition, the collapsible container is a receptacle dimensioned tointegrate into less than truck load operations.

According to yet another embodiment, a collapsible container includes apair of first opposing walls, each first opposing wall including aplurality of engaging hooks positioned outwardly along two opposingedges, a plurality of first engaging tabs positioned outwardly along anedge adjacent to the two opposing edges, a substantially flat edge andan exterior face comprising a graphic. The collapsible container alsoincludes a pair of second opposing walls, each second opposing wallincluding a plurality of slots positioned along two opposing edgesconfigured to accept the plurality of engaging hooks of the pair offirst opposing walls, a plurality of second engaging tabs positionedoutwardly along an edge adjacent to the two opposing edges, asubstantially flat edge, and an exterior face comprising a graphic. Thecollapsible container also includes a base comprising a plurality ofbase slots that are sized and positioned to accept the first and secondengaging tabs of the respective pairs of first and second opposing wallsto form a receptacle and a top panel configured to removably attach tothe substantially flat edge of the pairs of first and second opposingwalls. The collapsible container is dimensioned to integrate into lessthan truck load operations.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be more fully understood in viewof the drawings in which:

FIG. 1 is a perspective view of a collapsible container with one sideremoved according to one or more embodiments of the present invention.

FIG. 2 is an exploded view of a collapsible container according to oneor more embodiments of the present invention.

FIG. 3A is a front view of a first and second opposing wall of acollapsible container according to one or more embodiments of thepresent invention.

FIG. 3B is a top view of a base and a bottom view of a top panel of acollapsible container according to one or more embodiments of thepresent invention.

FIG. 4A is a front view of a first and second opposing wall of acollapsible container according to one or more embodiments of thepresent invention.

FIG. 4B is a top view of a base of a collapsible container according toone or more embodiments of the present invention.

FIG. 4C is a bottom view of a top panel of a collapsible containeraccording to one or more embodiments of the present invention.

FIG. 4D is a side view of a top panel of a collapsible containeraccording to one or more embodiments of the present invention.

FIG. 5A is a perspective view of a first opposing wall being insertedinto a base of a collapsible container according to one or moreembodiments of the present invention.

FIG. 5B is a perspective view of a second opposing wall being insertedinto a base of a collapsible container according to one or moreembodiments of the present invention.

FIG. 5C is a close up perspective view of a collapsible containeraccording to one or more embodiments of the present invention.

FIG. 5D is a front view of a collapsible container covered with a tarpaccording to one or more embodiments of the present invention.

The embodiments set forth in the drawings are illustrative in nature andare not intended to be limiting of the invention defined by the claims.Moreover, individual features of the drawings and the invention will bemore fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In one embodiment, a collapsible storage and shipping container isprovided. According to the embodiment, the container may be used forboth commercial and residential shipping and storing applications. Thecontainer, which may be made of a plastic material such as natural HDPE,for example, is designed and dimensioned to allow a motor carrier tointegrate pickup and delivery of the container into the motor carrier'scurrent less than load (LTL) operations without any additional equipmentor disruption of service. For example, according to some embodiments,the container may be loaded and unloaded at a dock or with a liftgate onthe trailer so the user or carrier is not required to provide equipmentsuch as a forklift or flatbed trailer. As described herein below,embodiments are dimensioned such that they are easily integrated currentLTL operations. Dimensioning of the containers ensures that space is notwasted within the trailer by minimizing gaps caused by oddly-dimensionedfreight and containers. According to some embodiments, the containerwill fit in all linehaul trailers, including, as an example and not alimitation, curtain side linehaul trailers, trailers with overheadroll-up doors and other types of linehaul trailers. Embodiments are alsodimensioned to allow the shipping and storage of oversized items, suchas couches, other large furniture, machines or equipment. The containermay be custom-sized to suit the user's shipping and storage needs.

The container is fully collapsible to provide efficient storage and/ortransport of the container when the container is empty, as well asprovide increased loading and unloading flexibility for the user.According to some embodiments, engaging tabs and hooks are configured tobe inserted into mating slots for easy assembly and collapsibility ofthe container. The container of this embodiment may be assembled anddisassembled without the use of, or need for, tools. Because thecontainer is collapsible, it may be collapsed during transport when thecontainer is empty, thereby decreasing the required volume of thecontainer within the linehaul trailer. This significantly increases theload capacity of the trailer, which frees up the motor carrier to loadthe trailer with more freight. Likewise, the user may collapse thecontainer when he or she is not presently using the container, therebytaking up less space within the storage area. The collapsibility alsoallows for increased loading and unloading flexibility. As an example,the freight to be loaded into the container for shipping and/or storagemay be placed on the base of the container before the attachment of thesides and top panel. A user may choose to remove just the top panel ofthe container when unloading an item from the container, or he or shemay additionally remove one or more sides to unload items that aredifficult to access from the container.

Embodiments may also comprise additional features. Freight securingmechanisms may be provided on the interior surface of the base accordingto some embodiments. The freight securing mechanisms allow freight to betied down or secured to the base of the container, thus preventingdamage to the freight during transport. Other embodiments may alsoinclude a tarp that covers the container for all-weather protection whenthe container is subject to the elements. Because conventionalcontainers may be unsightly, residential and commercial users may bereluctant to store items in a container in the exterior of their home orplace of business where the container may be seen from the road,sidewalk or other public vantage point. However, exterior storage may bedesirable where the user does not have adequate interior storage space,does not wish the store the item indoors, or for other reasons.Therefore, according to some embodiments, the exterior of the containermay comprise an aesthetically pleasing design. As an example and not alimitation, the design may include a playhouse, club house, fence,landscape scene, or any other pleasing design to disguise the container.

As shown in the illustrated embodiment of FIGS. 1 and 2, a collapsibleshipping and storage container 10 is provided. The embodimentillustrated in FIGS. 1 and 2 is of a square geometry (e.g., 48″×48″×48″among others). As described and illustrated herein, other geometries andsizes that integrate into LTL operations are also provided. Thecontainer comprises a base 16, a pair of first opposing walls 12, a pairof second opposing walls 12 and a top panel 18 that are configured toeasily attach to one another to form the collapsible container 10without the use of tools. The base 16 and the opposing walls 12, 14comprise engaging devices that are configured to interlock the base 16and the opposing walls 12, 14 to each other.

According to the embodiment of FIGS. 1 and 2, the engaging devicescomprise a plurality of male fastening components (e.g., 20, 24 and 26)and a plurality of female fastening components (e.g., 21, 25 and 27).More particularly, the male fastening components may include a pluralityof engaging hooks 20 (e.g., three on each side of the first opposingwalls 12 in this embodiment) and engaging tabs 24, 26, and the femalefastening components may comprise a plurality of slots 21, 25, 27. Theengaging hooks 20 of the illustrated embodiment are located along twoopposing sides of the pair of first opposing walls 12. It iscontemplated that the engaging hooks 20 may also be provided along twosides of the pair of second opposing walls 14. The engaging hooks 20 areconfigured to be inserted and secured to matching slots 21 providedalong two opposing sides of the pair of second opposing walls 14. Otherengaging device configurations are also possible. More specifically,rather than an fastening hook, an engaging tab with a hole or a notchconfigured for the insertion of a locking pin to fasten the wallstogether may also be employed.

The slots 25, 27 located on the base 16 are configured to accept thecorresponding engaging tabs 24, 26 of the pairs of first and second ofopposing walls 12, 14 (i.e., slot 25 is configured to accept engagingtab 24 and slot 27 is configured to accept engaging tab 26). The slots25, 27 and engaging tabs 24, 26 are dimensioned such that the pairs offirst and second opposing walls 12, 14 may only be inserted in thecorrect position on the base. For example, slot 25 and engaging tab 24may be of a length that is longer than slot 27 and engaging tab 26 orvisa versa. Similarly, slot 25 and engaging tab 24 may be of a widththat is wider than slot 27 and engaging tab 26 or visa versa. As isshown in FIG. 5A, the base 16 comprises support blocks 30 that provideadditional support for the container, as well as depth for the slots 25,27 to accept the engaging tabs 24, 26. The depth of the slots 25, 27increases the strength and rigidity of the container.

Referring again to FIGS. 1 and 2, the base 16 may contain support blocks30 as described above. The support blocks 30 form gaps within the base16 in which a forklift or other transporting device may be inserted tomove the container 10 to a specific location. The support blocks 30 alsoensure that the container 10 is sufficiently raised from the ground toprevent water from entering the container 10. According to someembodiments, freight securing mechanisms 28 may be provided throughoutthe floor of the base 16. In FIGS. 1 and 2, the freight securingmechanism 28 are positioned along the perimeter of the floor of the base16. The freight securing mechanism 28 may be used to secure freight tothe base and therefore container 10 by running a strap, bungee cord,rope, twine or other similar device under the latch or ring of thefreight securing mechanism 28 and around the freight (FIG. 5A). Manyother freight securing mechanism configurations are possible.

Additional embodiments may comprise handles 22 that are located on eachwall of the container 22. These handles 22 may be attached to theopposing walls 12, 14. Or, according to other embodiments and asillustrated in FIGS. 1 and 2, the handles 22 may be recesses that areformed into the plastic during the molding or formation of the opposingwalls 12, 14. The handles 22 may be used to lift and carry the container10 from one location or another. The handles 22 also aid in erecting andcollapsing the container 10, as well as assist in carrying and movingthe opposing walls 12, 14.

The top panel 18 of the container 10 is dimensioned such that there isan overhang above each opposing wall 12, 14. Under each overhang (i.e.,around the perimeter of the underside of the top panel 18) is a verticallip 29 that enfolds the walls 12, 14 when the container 10 is assembled,as may be viewed in the embodiment illustrated in FIG. 1. The verticallip 29 therefore secures the top panel 18 to the top portions of thewalls 12, 14 and ultimately, the container 10.

As described above, the container 10 may be designed and dimensioned ina number of sizes that allow the container 10 to be integrated into LTLoperations. FIGS. 3A and 3B illustrate an embodiment that is dimensionedas a rectangular container that is taller than the square embodiment ofFIGS. 1 and 2 (e.g., 48″×48″×75″). As an example, this embodiment may beuseful for storing and/or transporting a refrigerator or other tallitems. According to the embodiment of FIGS. 3A and 3B, the opposing sidewalls 12, 14 have four engaging hooks 20 and slots 21 along each side.FIGS. 4A-4C illustrate an embodiment in which the container 10 has ageometry suitable for storing and transporting large, oversized items(e.g., 48″×90″×55″). For example, this embodiment may be utilized totransport bicycles, four-wheelers, dressers, and other relatively longitems. The engaging tabs 24 a (FIG. 4A) and slots 25 a are relativelylonger than the engaging tabs 24 and slots 25 provided in theembodiments illustrated in FIGS. 1 and 2 and FIGS. 3A and 3B. Theincreased length of the engaging tabs 24 a and slots 25 a increase thestability of the container 10. Referring to FIG. 4C, the top of thecontainer 10 is composed of three top panel sections 18 a, 18 b, and 18c. The three section embodiment allows for easy access to the container10 as only a small section needs to be removed to access items withinthe container 10. Additionally, the three sections 18 a-18 c are easyfor a single person to install and remove as the pieces are smaller andlighter than one large top panel. According to the embodiment, aninterior engaging lip 29 b may be provided in addition to an exteriorengaging lip 29 a along portions of the three sections 18 a-18 c toincrease the stability of the container 10. Some embodiments comprisingthe three top sections 18 a-18 c may employ a notch fit to assemble thetop 18 onto the top of the container 10. As illustrated in FIG. 4D, 18 bmay comprise notch 52 which is configured to rest upon correspondingnotches 50 located on 18 a and 18 b. In this manner, all three sections18 a-18 c may be securely attached to first and second opposing walls12, 14.

FIGS. 5A-5D illustrate a method of erecting a collapsible container 10according to one embodiment. Referring initially to FIG. 5A, the base 16is placed on level surface. Freight may be placed on the base 16 at thistime, or any other time in the assembly process. Next, a first opposingwall 12 (i.e., a wall having male engaging structures 20) may be liftedby the handles 22 (not shown) so that the engaging tabs 24 are alignedwith the engaging slots 25. The wall 12 and engaging tabs 24 are thenpushed down into the engaging slots 25. This is repeated for the othersecond opposing wall 12.

Now referring to FIG. 5B, a second opposing wall 14 (i.e., a wall havingfemale engaging structures) may be lifted over the base 16 such that theengaging tabs 26 are aligned with the slots 27 on the base 16, and theengaging hooks 20 of the pair of first opposing walls 12 are alignedwith the slots 21 of the second opposing wall 14. After positioning thesecond opposing wall 14 into place, the wall 14 is then pushed down sothat the engaging tabs 26 enter the slots 27 and the engaging hooks 20of wall 12 grip and secure the wall 14. This is repeated for theremaining second opposing wall 14 having slots 21 such that all fouropposing walls 12, 14 are fitted and locked together to the base 16.

After the opposing walls 12, 14 are in place and the freight has beenloaded, the top panel 18 may be placed on the top portion of theopposing walls 12, 14 and fit into place, as illustrated in FIG. 5C. Thevertical lip 29 secures the top panel 18 to the opposing walls 12, 14.The container 10 is now fully assembled and ready for storage and/ortransport. According to some embodiments, a tarp 40 may be fitted overthe container to protect the container 10 from the elements, includingwind, rain, frost, snow and sun, for example (FIG. 5D). The tarp 40 maybe secured to the container 10 by flaps 42. The flaps 42 may be securedby attachments 44 a, 44 b which may be Velcro, or a loop in which a hookor a clip may use to engage attachment 44 a to attachment 44 b, forexample. The container 10 may be collapsed by removing the top panel 18,then removing the pair of second opposing walls 14 and finally the pairof first opposing walls 12. The base 16, opposing walls 12, 14 and toppanel 18 may then be stacked into a compact form for later use.

The foregoing description of the various embodiments of the inventionhas been presented for the purposes of illustration and description. Itis not intended to be exhaustive or to limit the invention to theprecise steps and/or forms disclosed. Many alternatives, modificationsand variations will be apparent to those skilled in the art of the aboveteaching. Moreover, although multiple inventive aspects have beenpresented, such aspects need not be utilized in combination, and variouscombinations of inventive aspects are possible in light of the variousembodiments provided above. Accordingly, the above description isintended to embrace all possible alternatives, modifications,combinations, and variations that have been discussed or suggestedherein, as well as all others that fall with the principles, spirit andbroad scope of the inventions as defined by the claims.

1. A collapsible container comprising: a base; a pair of first opposingwalls, each first opposing wall comprising a top edge, two side edgesand a bottom edge; a pair of second opposing walls, each second opposingwall comprising a top edge, two side edges and a bottom edge; a toppanel removably attached to the top edge of the pairs of first andsecond opposing walls; and a plurality of engaging devices positionedalong the perimeter of the base and along the two side edges and bottomedge of the pairs of first and second opposing walls; wherein: theplurality of engaging devices are configured to removably connect thepair of first opposing walls to the pair of second opposing walls and toremovably connect the pairs of first and second opposing walls to thebase; and the collapsible container is dimensioned to integrate intoless than truck load operations.
 2. A collapsible container as claimedin claim 1 wherein the plurality of engaging devices comprise aplurality of male fastening components and a plurality of femalefastening components, the plurality of female fastening componentsconfigured to accept the plurality of male fastening components.
 3. Acollapsible container as claimed in claim 1 wherein the plurality ofengaging devices comprise a plurality of engaging tabs and a pluralityof slots configured to accept the engaging tabs.
 4. A collapsiblecontainer as claimed in claim 1 wherein the plurality of engagingdevices comprise: a plurality of engaging hooks positioned outwardlyalong the two side edges of the pair of first opposing walls; aplurality of engaging tabs positioned outwardly along the bottom edge ofthe pairs of first and second opposing walls; and a plurality of slotspositioned along the two side edges of the pair of second opposing wallsand the perimeter of the base, the slots configured to accept theengaging hooks and the engaging tabs.
 5. A collapsible container asclaimed in claim 1 wherein the base further comprises a plurality ofsupport blocks spaced along the underside of the base such that aforklift may be used to lift the collapsible container.
 6. A collapsiblecontainer as claimed in claim 1 wherein the pairs of first and secondopposing walls comprise an exterior face having a graphic.
 7. Acollapsible container as claimed in claim 6 wherein the graphic depictsan outdoor scene, a playhouse, a building or a shed.
 8. A collapsiblecontainer as claimed in claim 1 wherein the collapsible container isdimensioned to fit in curtain side linehaul trailers and trailers withoverhead roll-up doors.
 9. A collapsible container as claimed in claim 1wherein the base, the pairs of first and second opposing walls and thetop panel are made of a plastic material.
 10. A collapsible container asclaimed in claim 1 wherein the collapsible container further comprises atarp.
 11. A collapsible container as claimed in claim 1 wherein thecollapsible container further comprises at least one freight securingmechanism configured to secure items within the collapsible container tothe base.
 12. A collapsible container as claimed in claim 11 wherein thefreight securing mechanism comprises a tie down positioned on aninterior face of the base.
 13. A collapsible container as claimed inclaim 11 wherein the freight securing mechanism comprises a latchpositioned on an interior face of the base.
 14. A collapsible containeras claimed in claim 1 wherein the base, the pairs of first and secondopposing walls, and the top panel are configured to be disassembled andstacked to minimize storage space of the collapsible container.
 15. Acollapsible container as claimed in claim 1 wherein the top panelfurther comprises at least one vertical lip along the perimeter of aninterior face of the top panel such that the vertical lip secures thetop panel to the pairs of first and second opposing walls.
 16. Acollapsible container as claimed in claim 15 wherein the top panelfurther comprises a first section, a second section and a third section.17. A collapsible container comprising: a pair of first opposing walls,each first opposing wall comprising: a top edge; a bottom edgecomprising a plurality of bottom male fastening components; and two sideedges comprising a plurality of side male fastening components; a pairof second opposing walls, each second opposing wall comprising: a topedge; a bottom edge comprising a plurality of bottom male fasteningcomponents; and two side edges comprising a plurality of side femalefastening components configured to accept the plurality of side malefastening components; a base comprising a plurality of base femalefastening components along a perimeter of the base, the plurality ofbase female fastening components configured to accept the plurality ofbottom male fastening components of the pairs of first and secondopposing walls; and a top panel configured to removably attach to thetop edge of the pairs of first and second opposing walls; wherein whenthe collapsible container is in an erected position, the collapsiblecontainer is a receptacle dimensioned to integrate into less than truckload operations.
 18. A collapsible container as claimed in claim 17wherein the base, the pairs of first and second opposing walls, and thetop panel are configured to be stacked when the collapsible container isin a collapsed position.
 19. A collapsible container comprising: a pairof first opposing walls, each first opposing wall comprising: aplurality of engaging hooks positioned outwardly along two opposingedges; a plurality of first engaging tabs positioned outwardly along anedge adjacent to the two opposing edges; a substantially flat edge; andan exterior face comprising a graphic; a pair of second opposing walls,each second opposing wall comprising: a plurality of slots positionedalong two opposing edges configured to accept the plurality of engaginghooks of the pair of first opposing walls; a plurality of secondengaging tabs positioned outwardly along an edge adjacent to the twoopposing edges; a substantially flat edge; and an exterior facecomprising a graphic; a base comprising a plurality of base slots thatare sized and positioned to accept the first and second engaging tabs ofthe respective pairs of first and second opposing walls to form areceptacle; and a top panel configured to removably attach to thesubstantially flat edge of the pairs of first and second opposing walls;wherein the collapsible container is dimensioned to integrate into lessthan truck load operations.
 20. A collapsible container as claimed inclaim 19 wherein in the length of the first engaging tabs is differentthan the length of the second engaging tabs.
 21. A collapsible containeras claimed in claim 19 wherein the collapsible container furthercomprises a plurality of freight securing mechanisms.
 22. A collapsiblecontainer as claimed in claim 21 wherein the plurality of freightsecuring mechanisms comprise tie downs positioned on an interior face ofthe base, the pairs of first and second opposing walls and the toppanel.
 23. A collapsible container as claimed in claim 21 wherein theplurality of freight securing mechanisms comprise latches positioned onan interior face of the base, the first and second pair of opposingwalls and the top panel.